Coke drum bottom de-heading system

ABSTRACT

The present invention features a coke drum de-heading system that includes a de-header valve. The de-header valve includes: (1) a main body; (2) a live loaded seat assembly coupled to the main body and comprising a dynamic, live loaded seat, a live seat adjustment mechanism coupled to the main body and designed to control and adjust the force and resulting seat load of the dynamic, live loaded seat, and a force transfer module in juxtaposition to the dynamic, live loaded seat for transferring the force from the live loaded seat adjustment mechanism to the dynamic, live loaded seat; (3) a static seat positioned opposite from and counteracting or counterbalancing the dynamic, live loaded seat; and (4) a blind or sliding blind capable moving in a linear, bi-directional manner within the de-header valve and between the dynamic, live loaded seat and the static seat.

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/151,055, now U.S. Pat. No. 8,679,299, filed on Jun. 13, 2005which is continuation of U.S. patent application Ser. No. 10/442,673,now U.S. Pat. No. 6,964,727, filed on May 20, 2003 which is acontinuation in part of U.S. patent application Ser. No. 09/946,917, nowU.S. Pat. No. 6,565,714, filed on Sep. 5, 2001 which claims priority toU.S. Provisional Patent Application Ser. No. 60/275,527 filed on Mar.12, 2001.

BACKGROUND

1. Field of the Invention

The present invention relates to a system and device for de-heading avessel containing a fluid, distillates, or unconsolidated debrisbyproduct, such as the several types of coke. Specifically, the presentinvention relates to a system and device, namely a de-header valve, thatis coupled to a coke drum, particularly at the top or bottom, whichserves to safely and effectively de-head the coke drum following themanufacture of coke, or other byproducts, and to facilitate the removalof coke during the decoking process.

2. Background

In the hydrocarbon processing industry, many refineries recover valuableproducts from the heavy residual oil that remains after refiningoperations are completed. This recovery process is known as delayedcoking and produces valuable distillates and coke in large vessels orcoke drums. Coke drums are usually in operation in pairs so that whenone coke drum is being filled with the byproduct or residual material,the feed may be directed to an empty drum so that the filled drum may becooled and the byproduct purged from the coke drum, a process known asdecoking. This allows the refinery process to operate in a continuousmanner, without undue interruption.

When one coke drum is full, it must be purged of the byproduct fed intoit. The drum is steam purged and cooled with quench water. The drum isthen drained of water and vented to atmospheric pressure, after whichthe top and bottom heads are removed (i.e. the coke drum is de-headed)to allow the coke to be cut from the drum and fall into a catch basin,typically a rail car. This process of de-heading the coke drum can beextremely dangerous for several reasons. To mention only a few, thecooling water introduced into the hot drums prior to the removal of thebottom head becomes extremely hot and could leak from the loosened headand scald surrounding operators, the load of un-drained water and loosecoke within the drum may exceed the limits of the support system andcause heavy equipment to fall, positioning the chute and necessaryremoval of the flanges or heads is done with operators who are in closeproximity to the drums, potentially falling coke may injure workers asthe heads are removed, and operating personnel may be exposed to finelydivided coke particles, steam, hot water and noxious gases, when thedrum is opened. Indeed several fatalities occur each year as a result ofthis manufacturing process. Once the coke is removed, the heads arereplaced and the coke drum is prepared to repeat the cycle.

Prior art systems and methods have tired to more efficiently andeffectively de-head coke drums, as well as to minimize many of thedangers inherent is the de-heading process. One such method involvesplacing a de-heading cart under the drum, raising a flange support ram,with braces installed, and loosening some (up to one half) of the flangebolts by manual operation with an impact wrench. Following the waterquench and drain, the remaining bolts are manually removed, braces areremoved from the ram, the approximately 4-ton flange is lowered, and thecart, with flange resting thereon, is moved away. This is extremelydangerous due to the manual labor requirements.

Other systems have been disclosed, which somewhat reduce human or manualinvolvement. For example, U.S. Pat. No. 4,726,109 to Malsbury et al. andU.S. Pat. No. 4,960,358 to DiGiacomo et al. describe a remote unheadingdevice for coking drums. The device includes a head unit for attachmentto a lower flange of a coking drum and a plurality of swing bolts whichare disconnected by remotely operated de-tensioning equipment. Aplatform device lowers the head unit, moves it laterally to one side andtips it for cleaning. A chute attached to the frame can be raised intoengagement with the coking drum lower flange for removal of coke fromthe drum.

U.S. Pat. No. 5,098,524 to Antalfy et al. filed on Dec. 10, 1990discloses a coke drum unheading device having a pivoting actuator systemoperable from a location remote from a drum outlet. The actuator isadapted to move a drum head between closed and open positions and toretain the drum head in a closed position under a load.

U.S. Pat. No. 5,500,094 to Fruchtbaum provides a coke drum unheadingdevice that retracts and tilts the bottom head incrementally so thatfalling debris such as shot coke can be caught by a chute. Followingdisposal of the loose debris, the head can be withdrawn from the area ofthe drum for maintenance. Specifically, the invention provides anunheading device for removing a bottom head from a flange on a lower endof a coke drum. An unheading car is horizontally movable into and fromposition below the bottom head. A vertically adjustable bottom headsupport member is mounted on the car. A bearing plate is pivotallymounted at an upper end of the support member for engaging a lowersurface of the bottom head. A retractable arm has first and secondsections hingedly connected at one end and having respective oppositeends secured to the bearing plate and the support member for pivotingthe bearing plate and bottom head supported thereon with respect tohorizontal, preferably to tilt the head towards an adjacent chute.

U.S. Pat. No. 5,581,864 to Rabet discloses an apparatus and methodenabling removal of the drum head of a coke drum, which comprises anapparatus remotely placing a carriage under the drum head and thecarriage is adapted to remotely engage the drum head, tightly supportthe head against the drum while workers are in the area, and to lowerthe head and carry it away. A safety feature is also included anddisclosed, wherein the carriage is normally supported by springs which,in the event of excessive loads, automatically transfers the loadcarrier to an overhead beam designed to carry any excessive loads.

Each of these prior art devices share common deficiencies in that theyare incapable of providing simple, efficient, and safe solutions to thede-heading of a coke drum. Specifically, each of the assemblies ordevices require that the head unit be completely removed from the flangeportion of the coke drum after each coking cycle and prior to thepurging of the coke from the coke drum. This creates an extreme hazardto workers and provides an inefficient and time consuming procedure.Removal of the head unit increases the chance for accident, while at thesame time increases human involvement as the head unit must be properlyplaced on the coke drum each time despite the automation involved. Inaddition, a large amount of floor space is required to accommodate thoseassemblies and devices that automate the removal and lifting of the headunit from the coke drum. Finally, such devices and systems may not beoperable in an environment where there the bottom headroom is less thanthe diameter of the bottom head.

SUMMARY AND OBJECTS OF THE INVENTION

In light of the problems and deficiencies inherent in prior art cokedrum deheading systems and devices, the present invention seeks toprovide a more efficient, cost-effective, and safe coke drum de-headingdevice and system.

Therefore, it is an object of the preferred embodiments of the presentinvention to provide a simplified and reliable coke drum de-headingsystem that does not require the physical removal of the coke drum headsafter each coking cycle, but rather comprises a mechanical de-headervalve that accomplishes the equivalent de-heading function of prior artdesigns.

It is another object of the preferred embodiments of the presentinvention to provide a coke drum de-heading system, wherein thede-header valve is removably coupled to the flanged portion of a cokedrum and adapted to de-head the coke drum without having to be removedafter each coking cycle.

It is still another object of the preferred embodiments of the presentinvention to provide a coke drum de-heading system having a dual seated,linear motion blind.

It is a further object of the preferred embodiments of the presentinvention to provide a coke drum de-heading system having a linearmotion blind as the only major moving part.

It is still a further object of the preferred embodiments of the presentinvention to provide a coke drum de-heading system that connects to thecoke drum via a flanged bolted connection.

It is still a further object of the preferred embodiments of the presentinvention to provide a coke drum de-heading system having dualindependent seats that provide double block and bleed and double blockand purge capabilities.

It is still a further object of the preferred embodiments of the presentinvention to provide a coke drum de-heading system having metal to metalseating.

A still further object of the preferred embodiments of the presentinvention is to provide one or more dynamic or live loaded seatsenergized from outside the process stream.

A still further object of the preferred embodiments of the presentinvention is to provide a system design having remote verification ofpositive isolation.

A still further object of the preferred embodiments of the presentinvention is to provide a system having instant and remote liveswitching to double block and vent mode from double block and purge modeupon loss of purge steam.

To achieve the foregoing objects, and in accordance with the inventionas embodied and broadly described herein, the present invention featuresa coke drum de-heading system that provides unique advantages over priorart de-heading systems, namely the de-heading of a coke drum withouthaving to physically remove the head units. This is essentiallyaccomplished using a specially designed de-header valve to be used in ade-header system.

Specifically, the de-header system comprises a dual seated, linearmotion goggle blind gate valve, or de-header valve, that is removablycoupled to and seals against the flanged portion of a coke drum much thesame way a conventional head unit would be attached. The de-header valveis equipped with a sliding blind having an orifice therein, a flatsurface adjacent the orifice, a stroke slightly greater than thediameter of the orifice in the de-header valve, and upper and lowerseats, wherein one of such seats is a dynamic, live loaded seat that iscapable of adjustment so as to seal the blind between the upper andlower seats. As such, the sliding blind can be moved in a substantiallylinear bi-directional manner between upper and lower seats, or dualseats, thus causing the orifice located thereon to move between an open,closed, and partially open position relative to the orifice in the cokedrum. In a closed position, the de-header valve and coke drum areprepared to receive the byproduct feed from the refinery process used tomanufacture coke. Once the drum is full, the valve may be actuatedcausing the sliding blind to open. In doing so, coke that hasaccumulated on the blind is sheared by the upper and lower seats, thusde-heading the coke drum and facilitating the removal of coke usingmethods commonly known in the art. The critical aspect of the presentinvention is its ability to provide a simple, yet effective de-headingsystem comprising a de-header valve having a sliding blind that movesback and forth between dual independent seats to de-head a coke drum andsimplify the decoking process. Another critical aspect of the presentinvention is the ability to de-head the coke drum without having toremove the head unit, and to do so at a remote location with little orno manual requirements.

In a preferred embodiment, the present invention features a coke drumde-heading system comprising (a) at least one coke drum containingmanufactured coke therein, wherein the coke drum has a top orifice and abottom orifice; (b) a de-header valve removably coupled to the coke drumand designed to facilitate the removal of coke from the coke drum byde-heading the coke drum and allowing the coke to pass there through;and (c) an exchange system, including an upper and lower bonnet andother elements and members adapted to integrate the de-heading system,and particularly the de-header valve, into the manufacturing system. Thede-header valve itself comprises (1) a main body having an orificedimensioned to align, in a concentric relationship, with either the topor bottom orifice of the coke drum when the de-header valve is coupledthereto; (2) a live loaded seat assembly coupled to the main body andcomprising a dynamic, live loaded seat, a live seat adjustment mechanismcoupled to the main body and designed to control and adjust the forceand resulting seat load of the dynamic, live loaded seat, and a forcetransfer module in juxtaposition to the dynamic, live loaded seat fortransferring the force from the live loaded seat adjustment mechanism tothe dynamic, live loaded seat; (3) a static seat positioned oppositefrom and counteracting or counterbalancing the dynamic, live loadedseat; and (4) a blind or sliding blind capable moving in a linear,bi-directional manner within the de-header valve and between thedynamic, live loaded seat and the static seat, the blind physicallycontrolled by an actuator and having a force exerted thereon by the dualseats, namely the dynamic, live loaded seat and the static seat, suchthat a seal is created between the dynamic, live loaded seat, the blind,and the static seat. In essence, the de-header valve de-heads the cokedrum and facilitates the removal of the coke from the coke drum uponactuation of the blind from a closed to an open position wherein thecoke is sheared.

The present invention further comprises a point to point sealing systemcomprising a plurality of loaded, independent, dual seats, preferablyfour, that seal directly against the gate. The seal consists of or is aresult of the metal to metal seating between the upper and lower seatsand the blind. Due to a dynamic, loaded upper seat, the amount of forcerequired to properly seal the seats to the gate is accomplished using alive load seat adjustment mechanism designed to control the amount offorce exerted on the blind.

As a result, the present invention provides a new and improved coke drumde-heading system. The system also utilizes pressure valves and steampurge inlet valves, as well as emergency vent valves to monitor andcontrol pressure within the system and to prevent inadvertent venting ofthe steam to atmosphere.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects and features of the present inventionwill become more fully apparent from the following description andappended claims, taken in conjunction with the accompanying drawings.Understanding that these drawings depict only typical embodiments of theinvention and are, therefore, not to be considered limiting of itsscope, the invention will be described and explained with additionalspecificity and detail through the use of the accompanying drawings inwhich:

FIG. 1 illustrates, generally, the refinery process, wherein coke ismanufactured from the refinery byproducts in a series of coke drums;

FIG. 2 illustrates the de-heading system of the present inventioncoupled a coke drum and an upper and lower bonnet;

FIG. 3 illustrates a front view of the coke drum de-heading systemaccording to the present invention, and an upper and lower bonnetattached thereto;

FIG. 4 illustrates a top view of the coke drum de-heading system showingthe orifice and the sliding blind contained therein;

FIG. 5 illustrates a cut away view of the de-header valve attached to acoke drum containing coke, and specifically, the sliding blind in apartially opened position and its relationship and interaction with thede-header valve as it being used to de-head the coke drum;

FIG. 6 illustrates an enlarged cut-away sectional view of the de-headervalve as it is attached to a coke drum containing manufactured coke, andparticularly, the de-header valve with the sliding blind in asubstantially closed position where coke accumulates on the surface ofthe sliding blind during the coking process;

FIG. 7 illustrates an enlarged cut-away sectional view of the de-headervalve as it is attached to a coke drum containing manufactured coke, andparticularly, the de-header valve with the sliding blind in a partiallyopened position as it is being used to de-head the coke drum;

FIG. 8 illustrates the workings of the live or dynamically loaded seatconcept and its relation to the sliding blind according to the presentinvention;

FIG. 9 illustrates a detailed view of the dynamic, live loaded seat andthe live seat adjustment mechanism;

FIG. 10 illustrates one embodiment of the dynamic, live loaded seat andlive seat adjustment mechanism;

FIG. 11 illustrates an alternative embodiment of the dynamic, liveloaded seat and live seat adjustment mechanism;

FIG. 12 illustrates a cut-away sectional view of an embodiment of thede-header valve having a groove in the seat for providing lubrication;

FIG. 13 illustrates a cut-away sectional view of another embodiment ofthe de-header valve having a groove in the seat for providinglubrication;

FIG. 14 illustrates a cut-away sectional view of another embodiment ofthe de-header valve having a groove in the seat for providinglubrication;

FIG. 14A illustrates the seat used in the embodiment of the de-headervalve depicted in FIG. 14;

FIG. 15 illustrates a cut-away sectional of another embodiment of thede-header valve having a groove in the seat for providing lubrication;and

FIGS. 16A and 16B each illustrate a different cut-away sectional view ofanother embodiment of the de-header valve having a groove in the seatfor providing lubrication and various channels for supplying lubricationinto the groove.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It will be readily understood that the components of the presentinvention, as generally described and illustrated in the figures herein,could be arranged and designed in a wide variety of differentconfigurations. Thus, the following more detailed description of theembodiments of the system, device, and method of the present invention,and represented in FIGS. 1 through 11, is not intended to limit thescope of the invention, as claimed, but is merely representative of thepresently preferred embodiments of the invention.

The presently preferred embodiments of the invention will be bestunderstood by reference to the drawings wherein like parts aredesignated by like numerals throughout. Although reference to thedrawings and a corresponding discussion follow below, it is firstadvantageous to provide a general background of the coking process,including the process of de-heading the coke drums at the end of amanufacturing cycle.

General Discussion on Delayed Coking and Coke De-Heading

In the typical delayed coking process, high boiling petroleum residuesare fed to one or more coke drums where they are thermally cracked intolight products and a solid residue—petroleum coke. The coke drums aretypically large cylindrical vessels having a top head and a conicalbottom portion fitted with a bottom head. The fundamental goal of cokingis the thermal cracking of very high boiling point petroleum residuesinto lighter fuel fractions. Coke is a byproduct of the process. Delayedcoking is an endothermic reaction with a furnace supplying the necessaryheat to complete the coking reaction in a drum. The exact mechanism isvery complex, and out of all the reactions that occur, only threedistinct steps have been isolated: 1) partial vaporization and mildcoking of the feed as it passes through the furnace; 2) cracking of thevapor as it passes through the coke drum; and 3) cracking andpolymerization of the heavy liquid trapped in the drum until it isconverted to vapor and coke. The process is extremelytemperature-sensitive with the varying temperatures producing varyingtypes of coke. For example, if the temperature is too low, the cokingreaction does not proceed far enough and pitch or soft coke formationoccurs. If the temperature is too high, the coke formed generally isvery hard and difficult to remove from the drum with hydraulic decokingequipment. Higher temperatures also increase the risk of coking in thefurnace tubes or the transfer line. As stated, delayed coking is athermal cracking process used in petroleum refineries to upgrade andconvert petroleum residuum (or resid) into liquid and gas productstreams leaving behind a solid concentrated carbon material, or coke. Afired heater is used in the process to reach thermal crackingtemperatures, which range upwards of 1,000° F. With short residence timein the furnace, coking of the feed material is thereby “delayed” untilit reaches large coking drums downstream of the heater. In normaloperations, there are two coke drums so that when one is being filled,the other may be purged of the manufactured coke. These coke drums arelarge structures that are approximately 25-30 meters in height and from4 to 9 meters in diameter. They are equipped with a top blind flangeclosure or orifice that is typically about 1.5 meters in diameter, and abottom blind flange orifice that is typically about 2 meters indiameter.

In a typical petroleum refinery process, several different physicalstructures of petroleum coke may be produced. These are namely, shotcoke, sponge coke, and/or needle coke, and are each distinguished bytheir physical structures and chemical properties. These physicalstructures and chemical properties also serve to determine the end useof the material. Several uses are available for manufactured coke, someof which include fuel for burning, the ability to be calcined for use inthe aluminum, chemical, or steel industries, or the ability to begasified to produce steam, electricity, or gas feedstock for thepetrochemicals industry.

To produce the coke, a delayed coker feed originates from the crude oilsupplied to the refinery and travels through a series of process membersand finally empties into one of the coke drums used to manufacture coke.A basic refinery flow diagram is presented as FIG. 1, with two cokedrums shown. The delayed coking process is a batch-continuous process,which means that the process is ongoing or continuous as the feed streamcoming from the furnace alternates filling between the two or more cokedrums. As mentioned, while one drum is on-line filling up with coke, theother is being stripped, cooled, decoked, and prepared to receiveanother batch. This is a timely process, with each batch in thebatch-continuous process taking approximately 12-20 hours to complete.In essence, hot oil, or resid as it is commonly referred to as, from thetube furnace is fed into one of the coke drums in the system. The oil isextremely hot and produces hot vapors that condense on the colder wallsof the coke drum. As the drum is being filled, a large amount of liquidruns down the sides of the drum into a boiling turbulent pool at thebottom. As this process continues, the hot resid and the condensingvapors cause the coke drum walls to heat. This naturally in turn, causesthe resid to produce less and less of the condensing vapors, whichultimately causes the liquid at the bottom of the coke drum to start toheat up to coking temperatures. After some time, a main channel isformed in the coke drum, and as time goes on, the liquid above theaccumulated coke decreases and the liquid turns to a more viscous typetar. This tar keeps trying to run back down the main channel which cancoke at the top, thus causing the channel to branch. This processprogresses up through the coke drum until the drum is full, wherein theliquid pools slowly turn to solid coke. When the first coke drum isfull, the hot oil feed is switched to the second coke drum, and thefirst coke drum is isolated, steamed to remove residual hydrocarbons,cooled by filling with water, opened, and then decoked. This cyclicalprocess is repeated over and over again in the manufacture of coke.

The decoking process is the process used to remove the coke from thedrum upon completion of the coking process. Due to the shape of the cokedrum, coke accumulates in the area near and attaches to the heads duringthe manufacturing process. To decoke the drum, the heads must first beremoved. Typically, once full, the drum is vented to atmosphericpressure and the top head (typically a 4-foot diameter flange) isunbolted and removed to enable placement of a hydraulic coke cuttingapparatus. After the cooling water is drained from the vessel, thebottom head (typically a 7-foot-diameter flange) is unbolted andremoved. This process is commonly known as “de-heading” and can be avery dangerous procedure because of the size of the flanges, the hightemperatures within the drum, potential falling coke, and other reasonsas mentioned above. Once the heads are removed, the coke is removed fromthe drum by drilling a pilot hole from top to bottom of the coke bedusing high pressure water jets. Following this, the main body of cokeleft in the coke drum is cut into fragments which fall out the bottomand into a collection bin, such as a bin on a rail cart, etc. The cokeis then dewatered, crushed and sent to coke storage or loadingfacilities.

Present Invention Coke Drum De-Heading System

Although the present invention is intended to cover both top and bottomde-heading systems, or rather the de-heading system of the presentinvention may be applicable and utilized on both the top and bottomopenings of a coke drum, the following detailed description andpreferred embodiments will be discussed in reference to a bottomde-heading system only. One ordinarily skilled in the art will recognizethat the invention as explained and described herein for a coke drumbottom de-heading system may also be designed and used as a coke drumtop de-heading system and the following discussion pertaining to thebottom de-heading system is not meant to be limiting to such.

The present invention describes a method and system for de-heading acoke drum following the manufacture of coke therein. As the presentinvention is especially adapted to be used in the coking process, thefollowing discussion will relate specifically in this manufacturingarea. It is foreseeable however, that the present invention may beadapted to be an integral part of other manufacturing processesproducing various elements other than coke, and such processes shouldthus be considered within the scope of this application.

The present invention comprises a system comprising a dual seated,linear motion, goggle blind valve, or de-header valve.

FIG. 1 depicts, generally, a petroleum manufacturing and refineryprocess 14 having several elements and systems present (identified, butnot discussed). In addition to these elements, petroleum manufacturingand refinery process 14 includes first and second delayed coke drums 18and 22, respectively. As mentioned, there are typically two coke drumsin simultaneous operation so as to permit the ongoing manufacture andrefinery of petroleum as well as its coke byproduct. While first cokedrum 18 is online and being filled via feed inlet 26, second coke drum22 is going through a decoking process to purge the manufactured cokecontained therein. Thereafter, when first coke drum 18 has reachedcapacity, feed inlet 26 is switched to second coke drum 22 that has justpreviously been purged of its contents, whereby first coke drum 18 isprimed for the decoking process where its contents will be purged. Thisprocess, commonly referred to as batch-continuous, allows the refineryto maintain continuous uninterrupted operation. Of course there may beonly one coke drum or a plurality of coke drums present. FIGS. 1 and 2also show the addition of coke drum de-heading system 10, includingde-header valve 12 and its place within the refinery process. AlthoughFIG. 1 is illustrative of a petroleum manufacturing and refinery processhaving two coke drums in series, and although the discussion andpreferred embodiments illustrated, described, and discussed herein focuson a coke drum de-heading system, one ordinarily skilled in the art willrecognize that the present invention may be applicable or adapted to anumber of different processes in which a function similar to the cokingprocess is present.

In reference to FIGS. 2 and 3, a general front view of coke drumde-heading system 10 is shown, with FIG. 2 showing system 10 attached orcoupled to first coke drum 18. In light of the identical nature andsetup of coke drum de-heading systems 10 on first and second coke drums18 and 22 respectively, only first coke drum 18 will be discussedthroughout the application. Specifically, coke drum de-heading system 10is removably coupled to coke drum 18 to allow the system to be removedif necessary. As shown, coke drum de-heading system 10 comprises ade-header valve 12 having a body 46 and upper and lower seats, 34 and 38respectively, attached thereto. Body 46 comprises a flanged portion 42that consists of substantially the same dimensions as the correspondingopening, whether flanged or otherwise, of coke drum 18. As shown,flanged portion 42 is coupled to flanged portion 30 on coke drum 18using those means known in the art, which is typically a bolted flangedconnection. Flanged portion 30 is a part of the “head” of coke drum 18.Depending upon the design of coke drum 18, de-header valve 12 may becoupled to flanged portion 30 or directly to the body of coke drum 18.The significance of the present invention, as opposed to prior artde-heading systems and devices, is that the coke drum de-heading system10 of the present invention does not require the “head” of the coke drumto be removed each time the drum is to be decoked. This significance isdiscussed at greater length below. Various sealing members and agentsare used to seal de-header valve 12 to coke drum 18 to preventinadvertent leaking.

Upper seat 34 and lower seat 38 are comprised of a dynamic, live loadedseat and a static seat, with the preferred configuration comprising adynamic live loaded upper seat 34, and a static lower seat 38. Analternative embodiment may comprise a dynamic, live loaded lower seatand a static upper seat. In the preferred embodiment, the static seat isa one piece seat that is securely fastened to de-header valve 12 and ispreferably non-adjustable. However, it is within the scope of thisinvention that both the upper and lower seats could be dynamic and/oradjustable, or that both the upper and lower seats could be static. Incontrast to the static seat, dynamic, live loaded seat is a moveable andadjustable seat that is energized from without the process stream vialive seat adjustment mechanism. The function of the dynamic, live loadedseat is to provide point to point fine tuning of the system, andparticularly the blind as it is sealed between upper and lower seats 34and 38. Various sealing members, such as O-rings, may be used to sealthe seats and their adjacent seat retainers to de-header valve 12.

FIGS. 2 and 3 also depict upper bonnet 54 and lower bonnet 58 coupled tobody 46 of de-header valve 12. Upper bonnet 54 and lower bonnet 58 areremovably coupled to body 46 using known means such as bolts 50 asshown. Upper bonnet 54 and lower bonnet 58 are shown having variouselements thereon to operate within the refinery process. Upper bonnet 54is shown equipped with steam purge outlet port 66 and an outlet steamtrap and orifice assembly 70. Upper bonnet also is shown having apressure transmitter 74 and a pressure gauge 78. Lower bonnet 58 isshown having a steam purge inlet port 82 and an inlet steam trap andorifice plate assembly 86 coupled thereto. Lower bonnet 58 also is shownhaving a vent valve assembly 90 and outlet pipe 94. Vent valve assemblyis located on a distal end of lower bonnet 58 and serves as an emergencyrelease. Upon the introduction of a pressure into the system that isabove the upper limit, emergency vent valve is activated, which releasespressure from the system and drains any excess fluid and gas throughpipe 94. Each of these additions are used to control and monitor thepressurized environment existing within the system. One ordinarilyskilled in the art will recognize the needed applications and devices tomaintain a suitable environment during the coking process.

In addition to the features mentioned above, upper and lower bonnets 54and 58, respectively, are independent of one another, yet may be incommunication with one another. For example, depending upon the systemrequirements and specifications, upper bonnet 54 may be pressurized andlower bonnet 58 may be purged to maintain system equilibriumrequirements.

FIGS. 2 and 3 are also illustrative of actuator 62 and ram 114. Actuator62 is used to drive ram 114, which provides the actual physical controlof the blind 106 (not shown) of de-header valve 12. Actuator 62 and ram114 provide the sliding lateral bi-directional movement to blind 106,which is used to open and close de-header valve 12 as needed. Asignificant advantage to the present invention is the ability tovirtually eliminate human or manual involvement or presence during themanufacturing process. For example, due to the design and functionalityof de-header valve 12 actuator 62 may be controlled or actuated from alocation remote from the actual site of the coke drums. As actuator 62is a hydraulic pump in a preferred embodiment, it is not necessary toactually activate actuator 62 at the site. Rather, any known means inthe art may be used to control actuator 62 a safe distance away from thecoke drums. As a result, the safety and ease of operation provide anadvantage not found in prior art designs. Actuator 62 and ram 114 areeach discussed in greater detail below in accordance with theircorresponding figure(s).

FIG. 4 illustrates a top view of coke drum de-heading system 10.Specifically, de-header valve 12 comprises a body 46 having an orifice98 surrounded by a flanged portion 42 used to couple the de-header valve12 to coke drum 18. Also shown is upper seat 34, which is a dynamic,live loaded seat contained within flanged portion 42. Although not shownin FIG. 4, de-header valve 12 comprises a lower static seat 38. Upperseat 34 and lower seat 38 serve to balance or support blind 106 as itmoves or slides in a bi-directional manner through de-header valve 12.Blind 106 is shown in FIG. 4 as comprising a flat surface 108 and anorifice 110 adjacent flat surface 108. Essentially, blind 106 moveslaterally within coke drum de-heading system 10 to open and closede-header valve 12. In a closed position, blind 106 is actuated and slidbetween upper seat 34 and lower seat 38, such that flat surface 108completely blocks the opening in coke drum 18. In this closed position,coke drum 18 is ready to receive inlet feed 26, wherein coke drum 18 isfilled with the petroleum byproduct, or resid, used to manufacture coke.Blind 106 is a dual seated blind, meaning that it is supported on eitherside from opposing or counteracting upper and lower seats 34 and 38,respectively. In addition, since upper seat 34 (or lower seat 38 in analternative embodiment) is a dynamic, live loaded seat having adjustableproperties, blind 106 is a “floating” blind in the sense that it isbiased as a result of the biased nature of dynamic, live loaded upperseat 34. When the device comprises static seat 34 and static seat 38,blind 106 moves within the tolerances between the space static seat 34and static seat 38 and the height or thickness of blind 106.

Upon actuation of actuator 62 and ram 114 coupled thereto and to blind106, blind 106 is caused to slide substantially laterally in abi-directional manner between upper seat 34 and lower seat 38 into anopen or partially open position, such that orifice 110 is brought intoalignment with orifice 98 of de-header valve 12, which in turn causesalignment with the opening in coke drum 18. In this position, coke drum18 may be decoked, or purged of its contents in traditional knownmethods. As such, flat surface 108 of blind 106 is retracted out of theway as blind 106 is slid in a substantially lateral manner in order tobring orifice 110 into proper alignment. Therefore, by sliding blind 106back and forth, de-header valve 12 is opened and closed as needed. Blind106 may be said to comprise a stroke having a distance long enough, suchthat blind 106 may close and seal de-header valve 12 using flat surface108, and open de-header valve 12 when orifice 110 is properly alignedwith orifice 98 and the opening in coke drum 18. The interim stages whenblind 106 is moving from a closed position to an open positionrepresents a critical aspect of the present invention as it is duringthese stages that the coke drum de-heading system performs the processof “de-heading” or “unheading” coke drum 18 in a significantly moreeffective and safe manner than prior art designs.

FIG. 5 is illustrative of a cut away view of de-header valve 12, andparticularly the relationship between de-header valve 12, having blind106, and coke drum 18. Actuator 62 (not shown) controls ram 114, whichcouples to blind 106 via attachment means 116. Actuator 62 is preferablya hydraulic pump capable of producing the required forces to slide blind106 in its substantially lateral manner within de-heading system 10. Asdiscussed, blind 106 is supported on either side by upper seat 34 andlower seat 38. As a result, and due to the nature of the cokemanufacturing process in which the system is under extreme temperatureand pressure, a large force must be applied to blind 106 from upper andlower seats 34 and 38, such that the system is substantially sealed andthe pressure within the system maintained. Due to the existence of adynamic, live loaded seat de-header valve 12, and particularly thedynamic, live loaded seat, is capable of modulating any bowing in blind106 that may exist during the coking process. The same effect can beaccomplished using a dual static set configuration. In a normal cokingprocess, extreme temperatures and pressures are present. Any variationin temperature between the upper and lower surfaces of the blind cancause the blind to bow. If the bowing is allowed to progress orcontinue, there is a danger in breaking the seal created between upperand lower seats 34 sand 38 and blind 106, which could cause damage tothe system and upset the manufacturing process. However, the ability ofthe present invention to adjust the load exerted on blind 106, utilizingthe dynamic, live loaded seat and its adjustment mechanism, or sealingbetween seat 34 and 38, provides a way to prevent, compensate for ormodulate any existing bowing that might occur. By increasing the appliedload of the dynamic, live loaded seat on blind 106, the bowing issubstantially eliminated, thus returning blind 106 to a more naturalshape.

In order to move blind 106, actuator 62 must be comprised of sufficientstrength so as to be able to overcome this initial seal and provide thenecessary force to slide blind 106 back and forth between an open andclosed position. One ordinarily skilled in the art will recognize thatother types of devices or systems may be used, other than a hydraulicpump, to actuate blind 106 and to overcome the forces exerted on blind106 by upper seat 34 and lower seat 38, thus this should not be limitingin any way.

FIG. 5 illustrates coke drum 18 coupled to and sealed to de-header valve12. Specifically, the flanged portions of each are coupled togetherusing commonly known means, such as a bolted connection. FIG. 5 isprimarily used to illustrate blind 106, having orifice 110 and flatsurface 108, and its service in de-heading coke drum 18. De-header valve12 is shown in a partially open position. In a closed position, flatsurface 108 would align with orifice 98 and the opening of coke drum 18,such that the system, and particularly coke drum 18, would be ready toreceive feed inlet 26. Blind 106 has an end portion that settles into ablind shroud 122 when de-header valve 12 is closed.

Coke drum 18 is also cut away to show the presence of coke 4 therein,and particularly coke head 6 and its relative position within system 10.During the manufacturing process, resid is pumped into coke drum 18,thereby ultimately producing coke 4 that is contained within coke drum18. In the beginning stages when coke drum 18 is being filled withresid, a large portion will naturally accumulate at the bottom of thedrum and on flat surface 108, thus forming a “head” near the opening ofde-header valve 12. This accumulation causes flat surface 108 of blind106 to be caked with coke. As the resid sets up and coke is formed, this“head” must be removed in order to decoke the entire drum and purge thedrum of the coke bed contained therein. This is essentially done by thepresent invention by sliding blind 106 from a closed position to an openposition. As can be seen in FIG. 5, blind 106 is supported by upper andlower seats 34 and 38. Not only is blind 106 supported, but rather largeforces are applied to blind 106 through these seats in order to enable asuitable pressurized environment. As such, the tolerances between upperand lower seats 34 and 38 and blind 106 are extremely tight. Because ofthese tight tolerances, and the accumulation of coke 4 on flat surface108, as blind 106 is displaced from its closed position, coke 4, andparticularly coke head 6, is sheared by upper seat 34 from off of flatsurface 108. This shearing effect breaks up the coke that hasaccumulated on blind 106, thus essentially de-heading coke drum 18,wherein coke drum 18 is prepared for the decoking process.

As a result of the load exerted upon blind 106 and resulting tighttolerances existing between blind 106 and upper and lower seats 34 and38, the substantially lateral bi-directional movement of blind 106between upper and lower seats 34 and 38 causes a grinding and polishingeffect to occur. In a preferred embodiment, upper and lower seats 34 and38, as well as blind 106 are made of metal, thus providing a metal tometal contact or metal to metal seal, or otherwise referred to as metalto metal seating of blind 106. This metal to metal seating is a uniqueaspect of the present invention in relation to coke drum de-heading. Themetal to metal seating increases the durability of the system as thereare no non-metal parts, such as vinyl or rubber, used to seal the seatsto blind 106. Metal to metal seating allows the system to achieve ahigher consistency of sealing, while at the same time providing extendedwear and durability. In addition, the metal to metal sealing allows thesystem, and specifically the sealing within the system, to be fine-tunedas discussed below.

Upper seat 34 and lower seat 38 are independent of one another andprovide definitive double block and bleed/double block and purgecapabilities.

A further feature of the present invention is the enclosure of theseating used to seal the system. Upper seat 34 and lower seat 38 arecompletely protected from the flow of material passing through orifice98, such that they are not in the direct line of flow. As such, there isa decreased chance of erosion to the finish of upper and lower seats 34and 38, as well as decreased erosion potential. This becomes critical inthat the present invention allows for fine-tuning of upper and lowerseats 34 and 38 to more directly and precisely control sealing on apoint to point basis against blind 106.

As a result of this type of seating, the metal to metal contact coupledwith the lateral bi-directional movement of blind 106 and the tighttolerances existing therein effectuates this polishing. This polishingeffect over time provides for much smoother transitions of blind 106between an open and closed position. In other words, the force requiredto displace blind 106 becomes less and less over time due to the smooth,polished metal to metal contact between upper and lower seats 34 and 38and blind 106. In addition to the metal to metal contact, upper andlower seats 34 and 38 may be finished, such as with a hardened chrome.Blind 106 may also be finished, such as with a nitride coating that isintegrated into the molecular structure of blind 106. Providing a finishto these elements creates significant advantages, such as increasedwear, thus prolonging their replacement, and increasing performancewhile in operation.

FIGS. 6 and 7 show de-header valve 12, and particularly blind 106, as itprogresses from a substantially closed position (FIG. 6) to asubstantially open position (FIG. 7), thus representing the interimstages when blind 106 is being slide laterally and coke drum 18 isessentially “de-headed.” As blind 106 is closed, coke 4 accumulates onflat surface 108 of blind 106, such that blind 106 is caked with coke.Once coke drum 18 is full, feed inlet 26 is switched off or routed to asecond coke drum. After the pre-coking steps are performed, the cokedrum must be de-headed in order to allow the rest of the coke bedcontained within the drum to be removed using standard procedures. Tode-head coke drum 18, an operator simply actuates actuator 62 from somelocation remote from the coking site, thus causing blind 106 to begin tomove laterally in a bi-directional manner within de-header valve 12. Asactuator 62 is initially activated, a large force is required to moveblind 106 due to the seal between blind 106 and upper and lower seats 34and 38 that must be broken and the initial shearing of coke 4 that hasaccumulated on flat surface 108 of blind 106. FIG. 6 shows how coke 4begins to break free and build up along the inside edge of upper seat 34as blind 106 is displaced. As blind 106 is displaced further, more coke4 is freed and builds up. In addition, as orifice 110 is brought intoalignment, that portion of coke 4 that has broken free is allowed todrop through orifice 98 of de-header valve 12 into catch basin 166.Catch basin 166 may be any known device or system known in the art, suchas a rail cart, etc.

FIG. 7 shows blind 106 in a more partially opened position. As can beseen, coke 4, and particularly coke head 6, is sheared from flat surface108 of blind 106 the more blind 106 is opened. The lateral displacementof blind 106 from a closed to an opened position serves to de-head cokedrum 18. The tight tolerance between upper and lower seats 34 and 38 andblind 106 are such that coke 4 is not allowed to pass under upper seat34, but is sheared off and contained within the seat boundaries. Coke 4should not pass under upper seat 34 as blind 106 is being opened as thiswould damage the polished surfaces being attained by the bi-directionalmovement of blind 106 between upper and lower seats 34 and 38. Onceopened, de-header valve 12 is not required to be removed from coke drum18 prior to decoking the entire drum. Essentially, workers may decokecoke drum 18 using standard procedures. Once finished, the operatorsimply deactivates actuator 62, such that blind 106 returns to a closedposition, whereby coke drum 18 may again be filled with resid and putthrough the identical process. A great advantage of the presentinvention, among others, is that there is only one main moving part(blind 106) used to de-head the coke drum and that this part is entirelyenclosed within a valve that may be attached to the coke drum withouthaving to be removed after each consecutive cycle.

FIGS. 8-11 represent the live loaded seat concept as applied to the cokedrum de-heading system 10, and specifically the de-header valve 12, ofthe present invention. FIG. 8 illustrates de-header valve 12 having alive loaded seat assembly 132 and a static seat assembly 136. Liveloaded seat assembly 132 is comprised of a dynamic live loaded seat,shown as upper seat 34, and a live seat adjustment mechanism 134 used toadjust and control the load exerted by the dynamic live loaded seat uponflat surface 108 of blind 106. Live loaded seat assembly 132 furthercomprises a force transfer module 162, shown in FIG. 8 as a wedgedmember, whose primary purpose is to transfer the load exerted by liveseat adjustment mechanism 134 to the dynamic live loaded seat, which inturn exerts a resulting force upon flat surface 108 of blind 106. Forcetransfer module 162, or wedged member, is constructed having an angledsection, which corresponds directly with a matching angled portion onthe dynamic, live loaded seat.

FIG. 8 also shows seat retaining rings 126, whose function is to secureand hold upper seat 34 in place within de-header valve 12. Seatretaining rings 126 are securely coupled to de-header valve 12, usingany number and orientation as necessary. Seat retaining rings 126 mustbe securely fastened so as to remain in a fixed position at all times.As shown, upper seat 34 exists as the dynamic live loaded seat describedherein. Lower seat 38, which is shown as a static seat, also is securedand held in place by a lower seat retaining ring similar to that as anupper seat retaining ring. Each of the seat retaining rings used inde-header valve 12 are coupled to de-header valve 12 using fasteningmeans 130, which are commonly known in the art.

FIG. 8 also provides an illustrative view of blind 106 and itsrelationship with upper seat 34 and lower seat 38. In essence, blind 106comprises a dual-seated linear motion blind having near zero tolerancesexisting between each of the upper and lower seats and the upper andlower surfaces of blind 106. Such tolerances are necessary to maintain asuitable pressurized environment during the manufacturing process. Asmentioned above, upper and lower seats 34 and 38 provide a metal tometal contact with blind 106 such that a seal is created withinde-header valve 12. This seal is important as there is a greater loadbetween the seat and the gate, than the load in coke drum 18. This sealenables de-header valve 12 to maintain a suitable pressurizedenvironment during the coke manufacturing process and is attained by theload exerted on blind 106 through dynamic live-loaded seat 34.

FIG. 9 illustrates an enlarged view of live-loaded seat assembly 132 asshown in FIG. 8. Live-loaded seat assembly 132 comprises live seatadjustment mechanism 134, force transfer module 162, and a dynamiclive-loaded seat, which is shown in FIG. 9 as upper seat 34. Each ofthese elements works in conjunction with one another to apply andtransfer force to blind 106, thus creating the necessary seal andde-heading function as earlier described. Live seat adjustment mechanism134 itself comprises housing 138, which houses and holds the elements oflive seat adjustment mechanism 134. Specifically, housing 138 hascontained therein a force applicator 142 that may be manually adjusteddepending on the amount and degree of force needed. In a preferredembodiment as shown in FIG. 10, force applicator 142 is simply athreaded member that may be rotated to increase or decrease the load onblind 106. Force applicator 142 is adjacent to and in contact withbiased plunger 146. Biased plunger 146 has distal and proximate endswith the distal end being in direct contact with force transfer module162. As force applicator 142 is activated to increase or decrease theload exerted on blind 106, biased plunger 147 is driven into forcetransfer module 162, which in turn exerts a resulting force on thedynamic live-loaded seat, or upper seat 34 as shown in FIG. 10, which inturn causes a resulting force to be exerted upon blind 106 at contact36. As mentioned, seat retaining rings 126 are securely fixed and willnot move, thus allowing wedged portion (force transfer module 162),which abuts seat retaining ring 126, to transfer force directly to blind106 through the dynamic, live loaded seat. The force applied by dynamic,live loaded seat to blind 106 is directly proportional to the forceapplied by force applicator 142. Thus, to increase the load on blind106, the operator simply activates force applicator 142. To decrease theload on blind 106, the operator simply deactivates force applicator 142as force applicator 142 is coupled to de-header valve 12 such that itmay be cycled in and out to adjust the pressure or force exerted onblind 106.

Force applicator 142 may be adjustable via manual means, such as athreaded bolt as shown, or via hydraulic or pneumatic means. Oneordinarily skilled in the art will recognize the possible ways to applypressure to force transfer module 162, while maintaining a seal. Inaddition, load bearing members may also be comprised of any suitablemeans capable of bearing a biased load and creating a loaded tensionforce upon force transfer module 162 and the dynamic, live loaded seat.

The dynamic live-loaded seat of the present invention is a biased seat,thus allowing a degree of longitudinal fluctuation of blind 106 bothduring the manufacturing process when coke drum 18 is being filled, aswell as when actuator 62 is activated or deactivated to cause blind 106to move from a closed position to an open position. This degree oflongitudinal motion results in blind 106 moving in a substantiallylateral manner. The biasing effect of the dynamic live-loaded seatresults from the configuration of live seat adjustment mechanism 134.Specifically, live seat adjustment mechanism 134 comprises a series ofbiasing elements or load bearing members 150, such as belevue washersand springs 154 that act in conjunction with plunger 146. By biasing thedynamic live-loaded seat, any physical variations or deflections inblind 106 during the manufacturing process or the de-coking process willbe absorbed through live-loaded seat assembly 132. This provides asignificant advantage as it is not uncommon for blind 106 to go throughvarious stages of deflection as a result of either pressure and/ortemperature differentials. The biased nature of the dynamic live-loadedseat will allow de-header valve 12 to maintain a workable pressurizedenvironment as well as to account for any physical or structural changesto de-header valve 12 as a result of the intense environment existing inthe manufacturing process.

Although not shown, the present invention of the dynamic seatingconfiguration utilizes four independent sets of dynamic seats such thatpoint to point adjustability is created within four loading zones. Thesefour loading zones significantly increase the ability to adjust andmanipulate the de-heading system according to the pressure within thesystem and the potential locations for leaking They also allow the useof components that need not be as true or smooth as those used withstatic seals. The four sets of dynamic seats could even be adjusted tothe point wherein an amount of force is applied to the blind such thatit is no longer moveable by the actuator. By allowing point to pointadjustability, the system is capable of being fine tuned to decrease thechances of unwanted leaks within the system. For example, if the systemwere leaking at one location, any one of, or multiple, dynamic seatscould be adjusted to compensate and seal the leak. The four points arelocated at approximately equidistant locations about flange 42.

FIG. 11 is illustrative of an alternative embodiment of live-loaded seatassembly 132.

In addition to the above-described and illustrated features, the systemof the present invention functions to control pressure within the systemand to prevent leakage into unwanted areas of the system, thus providingfor positive isolation. This isolation is accomplished through the useof close tolerances in the metal to metal seating, and resultingsealing. O-rings may also used to improve sealing. In addition, apositive pressure may be introduced from the outside of the valve toprevent venting of the feed stream to atmosphere or into parts of thevalve. The system provides for remote verification of positiveisolation. This means that steam may be added to the steam purge inletto pressurize the valve system outside of the sealed area. This pressuremay be used to isolate the feed stream which is at a lower pressure, orit may be used to check the efficiency of the seals. The system isdesigned to allow remote monitoring of this isolation pressure to verifythat the system is not leaking contaminants to atmosphere.

The system, and specifically the dual independent seats, also providesdefinitive double block and bleed/purge capabilities as well as instantand remote live switching to double block and vent mode from doubleblock and purge mode on loss of purge steam. The metal to metal sealbetween the gate and the upper and lower seats provide one method ofblocking leakage, along with the pressure from the outside of the sealswhich isolates the feed stream if the pressure is greater outside of theseal. If pressure is leaking, the system may be adjusted using the dualseats as described above to compensate or o-rings may be replaced.

The present invention also features a method for de-heading a coke drumfollowing the manufacture of coke therein. The method comprises thesteps of: (a) obtaining at least one coke drum designed for themanufacture of coke; (b) equipping the coke drum with a de-header valve,the de-header valve being removably coupled to the coke drum and itselfcomprising 1) a main body having means for connecting the de-headervalve to the coke drum; 2) a first seat coupled to the main body; 3) asecond seat coupled to the main body in an opposite or counteractingposition to the first seat; and 4) a blind coupled to the main body andactivated by an actuator, wherein the blind is capable of moving in asubstantially lateral bi-directional manner within the de-header valvebetween the upper and lower seats to control the opening and closing ofthe de-header valve, and the blind providing a seal between the firstloaded seat and the static seat; (c) closing the blind and sealing thefirst seat against the blind so as to seal the de-header valve; (d)manufacturing coke from a refinery process; and (e) de-heading the cokedrum by actuating the blind and causing it to slide across the firstseat and second seat into an open position, the first seat and secondseat thus shearing the coke in the coke drum as the blind is displaced.This method may be utilized on either a bottom or top de-heading system.

The present invention also contemplates different configuration of blind106. For example, blind 106 could be configured as shown in FIG. 12-14,or FIG. 13. In either embodiment, the opening and closing of drum 18 arestill provided. In FIG. 12, blind 106 is simply shorter and lacks anyopening 110. In FIG. 13, blind 106 comprises a recessed end. In FIG. 14,blind 106 comprises a rounded end. Alternatively, blind 106 could berounded as shown in FIG. 14 a.

The present invention also contemplates employing an actuator 62 thatprovides lateral force to two de-heading assemblies at the same timesuch that when one de-heading system is closed, the other is open.

In some embodiments of the present invention, a seat can contain agroove into which lubricant can be injected to provide lubricationbetween the seat and the blind during movement of the blind. As shown inFIG. 16A, seat 38 is shown containing a groove 1701 that extends alongat least a portion of the top surface of the seat. Groove 1701 includesone or more channels 1702 (two of which are indicated in FIG. 16A) whichextend downwardly into seat 38. Channels 1702 are used to supplylubricant into groove 1701. Any reasonable number of channels can beused to ensure that lubricant is distributed throughout groove 1701.

Body 46 can also include one or more channels which connect to thechannels 1702 to enable the lubricant to be supplied from an exterior ofbody 46. For example, FIG. 17 shows two entrance channels 1704, 1705which extend into body 46. Each entrance channel can be comprised of ahorizontal portion (1704 b, 1705 b respectively) and a vertical portion(1704 a, 1704 b respectively). Using a horizontal and vertical portionfacilitates drilling of the channels in body 46. Once formed, one of theopenings to the channel can be plugged to allow lubricant to be suppliedfrom the other opening to the channel.

An interior channel can also be formed within body 46 or seat 38 whichextends radially underneath groove 1701. Accordingly, channels 1702 canextend down into the interior channel, and vertical portions 1704 a,1705 a can extend up into the interior channel to form a continuouschannel from the exterior of body 46 to groove 1701.

In some embodiments, groove 1701 only extends along a portion of seat38. For example, because a portion (e.g. 180°) of seat 38 will beexposed while blind 106 is moved to the open position, and because thelubricant is often highly pressurized, groove 1701 can be limited to theportion of seat 38 that is not exposed during blind movement. Further,because of the high heat and pressure involved, a solid lubricant can beused which is carried to groove 1701 in a grease.

In addition to providing groove 1701 in the lower seat 38 of thede-header valve, a similar groove could also be provided within upperseat 34. In such embodiments, similar channels as those described abovecould be used to supply lubricant into the groove in upper seat 34.

In some embodiments of the present invention, upper seat 34 can includepacking 1710 as shown in FIG. 16B. Packing 16B provides a seal toprevent steam or other gases from escaping during stroking of the valve.For example, during stroking, the various components of upper seat 34can cause packing 1710 to compress.

An exemplary packing can comprise an inner wire mesh core and an outerweave. The inner wire mesh core can comprise an inconel or monel wovenwire mesh core, whereas the outer weave can comprise expanded graphitewith an oxidation resistant additive. The inner wire mesh core providesgreater resiliency, spring back, and recovery when packing 1710 iscompressed.

The present invention may be embodied in other specific forms withoutdeparting from its spirit of essential characteristics. The describedembodiments are to be considered in all respects only al illustrativeand not restrictive. The scope of the invention is, therefore, indicatedby the appended claims, rather than by the foregoing description. Allchanges which come within the meaning and range of equivalency of theclaims are to be embraced within their scope.

What is claimed is:
 1. A coke drum de-heading system comprising: a cokedrum having a flanged orifice; a de-header valve removably coupled tosaid flanged orifice of said coke drum and comprising: a body a firstseat attached to the body; a second seat aligned in opposition to thefirst seat attached to the body; and a blind actuated by an actuator,said blind capable of moving in a bi-directional manner within saidde-header valve between an exterior surface of the first and the secondseat to control the opening and closing of said de-header valve and toshear said coke from said blind when said blind is caked with coke;wherein the exterior surface of the second seat includes a groove intowhich grease containing solid lubricants is flowed to providelubrication between the exterior surface of the second seat and theblind while the blind is moved in the bi-directional manner, the grooveincluding one or more channels through which the grease is injected intothe groove; and wherein the body contains one or more channels whichconnect to the one or more channels in the groove through which thegrease is flowed from an exterior of the body into the one or morechannels in the groove.
 2. The coke drum de-heading system of claim 1,wherein the groove extends along only a portion of the exterior surfaceof the second seat.
 3. The coke drum de-heading system of claim 2,wherein the portion is 180° of the second seat.
 4. The coke drumde-heading system of claim 1, wherein the second seat is the bottom seatof the de-header valve such that the groove extends along the topsurface of the second seat.
 5. The coke drum de-heading system of claim1, wherein the one or more channels in the body comprise one or moreentrance channels which extend from the exterior of the body into theinterior of the body, and an interior channel which extends radiallyunderneath the second seat, and wherein the one or more channels in thegroove extend vertically down through the second seat and into theinterior channel in the body.
 6. The coke drum de-heading system ofclaim 5, wherein the one or more entrance channels each comprise ahorizontal portion and a vertical portion, the horizontal portionextending inwardly from an exterior surface of the body to the verticalportion, and the vertical portion extending vertically into the interiorchannel.
 7. The coke drum de-heading system of claim 5, wherein the oneor more entrance channels comprise two entrance channels.
 8. The cokedrum de-heading system of claim 7, wherein the two entrance channels arepositioned in the body opposite one another.
 9. The coke drum de-headingsystem of claim 1, wherein the first seat includes a packing comprisedof an inner wire mesh core and an outer weave.
 10. The coke drumde-heading system of claim 9, wherein the inner wire mesh core comprisesa inconel or monel woven wire mesh core.
 11. A coke drum de-header valvecomprising: a body a first seat attached to the body; a second seataligned in opposition to the first seat attached to the body; and ablind actuated by an actuator, said blind capable of moving in abi-directional manner within said de-header valve between an exteriorsurface of the first and the second seat to control the opening andclosing of said de-header valve and to shear coke from said blind whensaid blind is caked with coke; wherein the exterior surface of thesecond seat includes a groove into which grease containing solidlubricants is flowed to provide lubrication between the exterior surfaceof the second seat and the blind while the blind is moved in thebi-directional manner, the groove including one or more channels throughwhich the grease is injected into the groove; and wherein the bodycontains one or more channels which connect to the one or more channelsin the groove through which the grease is flowed from an exterior of thebody into the one or more channels in the groove.
 12. The coke drumde-header valve of claim 11, wherein the groove extends along only aportion of the exterior surface of the second seat.
 13. The coke drumde-header valve of claim 12, wherein the portion is 180° of the secondseat.
 14. The coke drum de-header valve of claim 11, wherein the secondseat is the bottom seat of the de-header valve such that the grooveextends along the top surface of the second seat.
 15. The coke drumde-header valve of claim 11, wherein the one or more channels in thebody comprise one or more entrance channels which extend from theexterior of the body into the interior of the body, and an interiorchannel which extends radially underneath the second seat, and whereinthe one or more channels in the groove extend vertically down throughthe second seat and into the interior channel in the body.
 16. The cokedrum de-header valve of claim 15, wherein the one or more entrancechannels each comprise a horizontal portion and a vertical portion, thehorizontal portion extending inwardly from an exterior surface of thebody to the vertical portion, and the vertical portion extendingvertically into the interior channel.
 17. The coke drum de-header valveof claim 15, wherein the one or more entrance channels comprise twoentrance channels.
 18. The coke drum de-header valve of claim 17,wherein the two entrance channels are positioned in the body oppositeone another.
 19. The coke drum de-header valve of claim 11, wherein thefirst seat includes a packing comprised of an inner wire mesh core andan outer weave.
 20. The coke drum de-header valve of claim 19, whereinthe inner wire mesh core comprises a inconel or monel woven wire meshcore.